Personal Care & Hygiene

Manufacturing products that are applied to the body, such as cosmetics, fragrances and shampoo, require myriad testing not only for function but safety. Competition among manufacturers is fierce, as constant improvements are required to stay ahead of cultural trends and consumer demands. The manufacturing cycle is, therefore, intense and short.

The complex process of creating mixtures that will perform well under a variety of conditions — such as meso or micro mixing, crystallization, precipitation and suspension — is best achieved by using fluid dynamics for virtual testing. Such analysis allows product engineers to gather information such as effectiveness, product decomposition and performance under various conditions, which can be difficult to observe through traditional testing methods.

Dynamic simulation of long hairs in liquid stream

ANSYS offers an unequalled depth of solutions that can aid product engineers in the manufacturing process. A range of simulations can be set up to test for how a product will perform in various temperatures, and dilutions; multiple simulations together can provide a realistic statistical representation and characterization of performance of various formulations.

For example, one of the most critical parameters in blending a liquid is the time it takes to achieve the correct mixture. Using fluid dynamics analysis, mixing process simulation can be performed in an hour. Advanced simulations can take place over days and weeks, as opposed to months in more-traditional physical testing — reducing the time to market.

Emulsions, the basis of many personal care products, require that quality be maintained from production through shelf life. The concern that the texture of the emulsion will be altered during the course of preparation or packaging, or during shelf life, can be tested using 2-D and 3-D virtual simulation.

Another case in point: Producing products for use in an atomizer spray involves modeling the gas–liquid interface during the generation of droplets from a container through a nozzle. Simulation technology allows product designs to view atomization under varying operating conditions; engineers can then map out a design for the successful operation of the nozzle. Simulation provides an understanding of how the spray will affect the characteristics of the product, and helps in tailoring a nozzle design for the liquid being dispersed.

Nonisothermal interactions between complex fluids and the structural behavior of the packaging or manufacturing equipment can be applied to bottle squeeze, drop test, wicking, drying, gluing, printing and other models.

Using ANSYS software tools to predict how a product will hold up under various conditions allows manufacturers to get products to market as efficiently as possible, while meeting customer expectations for the best product at the best price.